U.S. patent application number 15/751995 was filed with the patent office on 2018-08-23 for wear resistant parts and fabrication.
The applicant listed for this patent is Schlumberger Technology Corporation. Invention is credited to Kjell Haugvaldstad, Jonathan Luke James, Stuart Alan Kolbe, Svein Olav Vikan.
Application Number | 20180236580 15/751995 |
Document ID | / |
Family ID | 57983571 |
Filed Date | 2018-08-23 |
United States Patent
Application |
20180236580 |
Kind Code |
A1 |
Kolbe; Stuart Alan ; et
al. |
August 23, 2018 |
Wear Resistant Parts and Fabrication
Abstract
A wear resistant part includes a first material including a
structure having a surface feature. The first material is capable
of maintaining its structure at a temperature from about
1000.degree. C. to about 1500.degree. C. (e.g., upon exposure to
the temperature or upon being heated to reach the temperature). The
wear resistant part also includes a second material formed into a
shape extending partially around the structure of the first
material while exposing the surface feature of the first material.
The shape of the second material is formed by a matrix infiltration
at a temperature from about 1000.degree. C. to about 1500.degree.
C.
Inventors: |
Kolbe; Stuart Alan;
(Stonehouse, GB) ; James; Jonathan Luke;
(Stonehouse, GB) ; Haugvaldstad; Kjell;
(Trondheim, NO) ; Vikan; Svein Olav; (Trondheim,
NO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Schlumberger Technology Corporation |
Sugar Land |
TX |
US |
|
|
Family ID: |
57983571 |
Appl. No.: |
15/751995 |
Filed: |
August 10, 2016 |
PCT Filed: |
August 10, 2016 |
PCT NO: |
PCT/US2016/046220 |
371 Date: |
February 12, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62204397 |
Aug 12, 2015 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E21B 34/06 20130101;
E21B 17/10 20130101; B23K 2103/52 20180801; B23K 1/0008
20130101 |
International
Class: |
B23K 1/00 20060101
B23K001/00; E21B 34/06 20060101 E21B034/06 |
Claims
1. A wear resistant part comprising: a first material including a
structure having at least one surface feature, the first material
capable of maintaining its structure at a temperature from about
1000.degree. C. to about 1500.degree. C.; and a second material
formed into a shape extending partially around the structure of the
first material while exposing the at least one surface feature of
the first material, the shape of the second material formed by a
matrix infiltration at a temperature from about 1000.degree. C. to
about 1500.degree. C.
2. The wear resistant part as recited in claim 1, wherein the first
material comprises at least one of a ceramic material or a sintered
tungsten carbide material.
3. The wear resistant part as recited in claim 1, wherein the
second material comprises an infiltrated tungsten carbide
material.
4. The wear resistant part as recited in claim 1, wherein a surface
of the first material in contact with the second material is
metalized.
5. The wear resistant part as recited in claim 4, wherein the
metalized surface of the first material is for bonding with the
second material during the matrix infiltration.
6. A method comprising: receiving a structure having at least one
surface feature, the structure formed of a first material capable
of maintaining the structure at a temperature from about
1000.degree. C. to about 1500.degree. C.; forming, by a matrix
infiltration at a temperature from about 1000.degree. C. to about
1500.degree. C., a second material into a shape that can extend
partially around the structure of the first material while exposing
the at least one surface feature of the first material; and
connecting the second material to the first material.
7. The method as recited in claim 6, wherein the first material
comprises at least one of a ceramic material or a sintered tungsten
carbide material.
8. The method as recited in claim 6, wherein the second material
comprises an infiltrated tungsten carbide material.
9. The method as recited in claim 6, wherein forming the second
material into the shape that can extend partially around the
structure of the first material comprises forming the second
material partially around the first material by the matrix
infiltration.
10. The method as recited in claim 6, wherein a surface of the
first material in contact with the second material is
metalized.
11. The method as recited in claim 10, wherein connecting the
second material to the first material comprises brazing the first
material to the second material.
12. The method as recited in claim 10, wherein forming the second
material into the shape that can extend partially around the
structure of the first material comprises forming the second
material partially around the first material by the matrix
infiltration, and the metalized surface of the first material is
for bonding with the second material during the matrix
infiltration.
13. A wear resistant part comprising: a first material including a
structure having at least one surface feature, the first material
capable of maintaining its structure at a temperature from about
1000.degree. C. to about 1500.degree. C.; and a second material
connected to the first material, the second material formed into a
shape extending partially around the structure of the first
material while exposing the at least one surface feature of the
first material, the shape of the second material formable by a
matrix infiltration at a temperature from about 1000.degree. C. to
about 1500.degree. C.
14. The wear resistant part as recited in claim 13, wherein the
first material comprises at least one of a ceramic material or a
sintered tungsten carbide material.
15. The wear resistant part as recited in claim 13, wherein the
second material comprises an infiltrated tungsten carbide
material.
16. The wear resistant part as recited in claim 13, wherein the
second material is formed partially around the first material by
the matrix infiltration.
17. The wear resistant part as recited in claim 13, wherein a
surface of the first material in contact with the second material
is metalized.
18. The wear resistant part as recited in claim 17, wherein the
first material is brazed to the second material.
19. The wear resistant part as recited in claim 17, wherein the
second material is formed partially around the first material by
the matrix infiltration, and the metalized surface of the first
material is for bonding with the second material during the matrix
infiltration.
20. The wear resistant part as recited in claim 13, wherein the
surface feature comprises a high tolerance feature.
Description
RELATED APPLICATIONS
[0001] This application claims the benefit of a related U.S.
Provisional Application Ser. No. 62/204,397 filed on Aug. 12, 2015,
entitled HIGH MELTING POINT INSERTS FOR BONDING OR CASTING TO
INFILTRATED TUNGSTEN CARBIDE to Stuart Alan Kolbe et al., the
disclosure of which is incorporated by reference herein in its
entirety.
BACKGROUND
[0002] Oil wells are created by drilling a hole into the earth
using a drilling rig that rotates a drill string (e.g., drill pipe)
having a drill bit attached thereto. The drill bit, aided by the
weight of pipes (e.g., drill collars) cuts into rock within the
earth. Drilling fluid (e.g., mud) is pumped into the drill pipe and
exits at the drill bit. The drilling fluid may be used to cool the
bit, lift rock cuttings to the surface, at least partially prevent
destabilization of the rock in the wellbore, and/or at least
partially overcome the pressure of fluids inside the rock so that
the fluids do not enter the wellbore.
SUMMARY
[0003] Aspects of the disclosure can relate to a wear resistant
part that includes a first material including a structure having a
surface feature. The first material is capable of maintaining its
structure at a temperature from about 1000.degree. C. to about
1500.degree. C. (e.g., upon exposure to the temperature or upon
being heated to reach the temperature). The wear resistant part
also includes a second material formed into a shape extending
partially around the structure of the first material while exposing
the surface feature of the first material. The shape of the second
material is formed by a matrix infiltration at a temperature from
about 1000.degree. C. to about 1500.degree. C.
[0004] Other aspects of the disclosure can relate to a method for
forming a wear resistant part from a first material and a second
material. The method can include receiving a structure having at
least one surface feature, where the structure is formed of a first
material capable of maintaining the structure at a temperature from
about 1000.degree. C. to about 1500.degree. C. (e.g., upon exposure
to the temperature or upon being heated to reach the temperature).
The method can also include forming, by a matrix infiltration at a
temperature from about 1000.degree. C. to about 1500.degree. C., a
second material into a shape that can extend partially around the
structure of the first material while exposing the at least one
surface feature of the first material. The method can also include
connecting the second material to the first material.
[0005] Also, aspects of the disclosure can relate to a wear
resistant part that includes a first material including a structure
having at least one surface feature. The first material is capable
of maintaining its structure at a temperature from about
1000.degree. C. to about 1500.degree. C. (e.g., upon exposure to
the temperature or upon being heated to reach the temperature). The
wear resistant part also includes a second material connected to
the first material. The second material is formed into a shape
extending partially around the structure of the first material
while exposing the at least one surface feature of the first
material. The shape of the second material is formable by a matrix
infiltration at a temperature from about 1000.degree. C. to about
1500.degree. C.
[0006] This summary is provided to introduce a selection of
concepts that are further described below in the detailed
description. This summary is not intended to identify key or
essential features of the claimed subject matter, nor is it
intended to be used as an aid in limiting the scope of the claimed
subject matter.
FIGURES
[0007] Embodiments of wear resistant parts and fabrication thereof
are described with reference to the following figures. The same
numbers are used throughout the figures to reference like features
and components.
[0008] FIG. 1 illustrates an example system in which embodiments of
wear resistant parts and fabrication can be implemented;
[0009] FIG. 2 is a cross-sectional isometric view illustrating
various components of an example device that can implement
embodiments of wear resistant parts and fabrication;
[0010] FIG. 3 is a cross-sectional exploded isometric view of the
components illustrated in FIG. 2;
[0011] FIG. 4 is a cross-sectional isometric view illustrating
various components of an example device that can implement
embodiments of wear resistant parts and fabrication;
[0012] FIG. 5 is a cross-sectional exploded isometric view of the
components illustrated in FIG. 4; and
[0013] FIG. 6 illustrates example method(s) for forming a wear
resistant part from a first material and a second material in
accordance with one or more embodiments.
DETAILED DESCRIPTION
[0014] The material or materials from which a tool is fabricated
can influence the durability and associated structural
characteristics of the particular tool and can influence the
operating environment in which the tool can be employed. For
systems used in highly abrasive environments, wear of system
components can lead to downtime of the systems, which can influence
throughput of applications in the highly abrasive environments.
Such applications can include, but are not limited to, drilling
applications, boring applications, and mining applications.
Further, the operation of a first tool component can influence the
structural integrity of a second tool component. For example,
operation of a rotary valve can introduce a rotor spinning relative
to an operating surface of a stator. Such operation can introduce
wear to mated regions of the rotor and stator, where replacement of
either or both of the rotor and the stator can affect the operating
life of the rotary valve.
[0015] Aspects of the present disclosure relate to wear resistant
parts, where in some embodiments, the wear resistant parts can form
at least a portion of a tool or system that can be used in highly
abrasive environments. The wear resistant parts can form a surface
feature (e.g., an operating surface, such as a running surface,
bushing surface, or so forth) that is exposed following connection
between a first material and a second material, the materials that
provide shape and structure to the wear resistant part. In some
embodiments, the wear resistant parts can be included in a valve
(e.g., a rotary valve), a piston, a flow channel, a bearing, a
filter, a stabilizer, a flow diverter, or other tools or systems.
As described herein, drilling applications are provided by way of
example and are not meant to limit the present disclosure. In other
embodiments, systems, techniques, and apparatus as described herein
can be used with other down hole operations. Further, such systems,
techniques, and apparatus can be used in other applications not
necessarily related to down hole operations.
[0016] FIG. 1 depicts a wellsite system 100 in accordance with one
or more embodiments of the present disclosure. The wellsite can be
onshore or offshore. A borehole 102 is formed in subsurface
formations by directional drilling. A drill string 104 extends from
a drill rig 106 and is suspended within the borehole 102. In some
embodiments, the wellsite system 100 implements directional
drilling using a rotary steerable system (RSS). For instance, the
drill string 104 is rotated from the surface, and down hole devices
move the end of the drill string 104 in a desired direction. The
drill rig 106 includes a platform and derrick assembly positioned
over the borehole 102. In some embodiments, the drill rig 106
includes a rotary table 108, kelly 110, hook 112, rotary swivel
114, and so forth. For example, the drill string 104 is rotated by
the rotary table 108, which engages the kelly 110 at the upper end
of the drill string 104. The drill string 104 is suspended from the
hook 112 using the rotary swivel 114, which permits rotation of the
drill string 104 relative to the hook 112. However, this
configuration is provided by way of example and is not meant to
limit the present disclosure. For instance, in other embodiments a
top drive system is used.
[0017] A bottom hole assembly (BHA) 116 is suspended at the end of
the drill string 104. The bottom hole assembly 116 includes a drill
bit 118 at its lower end. In embodiments of the disclosure, the
drill string 104 includes a number of drill pipes 120 that extend
the bottom hole assembly 116 and the drill bit 118 into
subterranean formations. Drilling fluid (e.g., mud) 122 is stored
in a tank and/or a pit 124 formed at the wellsite. The drilling
fluid 122 can be water-based, oil-based, and so on. A pump 126
displaces the drilling fluid 122 to an interior passage of the
drill string 104 via, for example, a port in the rotary swivel 114,
causing the drilling fluid 122 to flow downwardly through the drill
string 104 as indicated by directional arrow 128. The drilling
fluid 122 exits the drill string 104 via ports (e.g., courses,
nozzles) in the drill bit 118, and then circulates upwardly through
the annulus region between the outside of the drill string 104 and
the wall of the borehole 102, as indicated by directional arrows
130. In this manner, the drilling fluid 122 cools and lubricates
the drill bit 118 and carries drill cuttings generated by the drill
bit 118 up to the surface (e.g., as the drilling fluid 122 is
returned to the pit 124 for recirculation). Further,
destabilization of the rock in the wellbore can be at least
partially prevented, the pressure of fluids inside the rock can be
at least partially overcome so that the fluids do not enter the
wellbore, and so forth.
[0018] In embodiments of the disclosure, the drill bit 118
comprises one or more crushing and/or cutting implements, such as
conical cutters and/or bit cones having spiked teeth (e.g., in the
manner of a roller-cone bit). In this configuration, as the drill
string 104 is rotated, the bit cones roll along the bottom of the
borehole 102 in a circular motion. As they roll, new teeth come in
contact with the bottom of the borehole 102, crushing the rock
immediately below and around the bit tooth. As the cone continues
to roll, the tooth then lifts off the bottom of the hole and a
high-velocity drilling fluid jet strikes the crushed rock chips to
remove them from the bottom of the borehole 102 and up the annulus.
As this occurs, another tooth makes contact with the bottom of the
borehole 102 and creates new rock chips. In this manner, the
process of chipping the rock and removing the small rock chips with
the fluid jets is continuous. The teeth intermesh on the cones,
which helps clean the cones and enables larger teeth to be used. A
drill bit 118 comprising a conical cutter can be implemented as a
steel milled-tooth bit, a carbide insert bit, and so forth.
However, roller-cone bits are provided by way of example and are
not meant to limit the present disclosure. In other embodiments, a
drill bit 118 is arranged differently. For example, the body of the
drill bit 118 comprises one or more polycrystalline diamond compact
(PDC) cutters that shear rock with a continuous scraping
motion.
[0019] In some embodiments, the bottom hole assembly 116 includes a
logging-while-drilling (LWD) module 132, a measuring-while-drilling
(MWD) module 134, a rotary steerable system 136, a motor, and so
forth (e.g., in addition to the drill bit 118). The
logging-while-drilling module 132 can be housed in a drill collar
and can contain one or a number of logging tools. It should also be
noted that more than one LWD module and/or MWD module can be
employed (e.g. as represented by another logging-while-drilling
module 138). In embodiments of the disclosure, the logging--while
drilling modules 132 and/or 138 include capabilities for measuring,
processing, and storing information, as well as for communicating
with surface equipment, and so forth.
[0020] The measuring-while-drilling module 134 can also be housed
in a drill collar, and can contain one or more devices for
measuring characteristics of the drill string 104 and drill bit
118. The measuring-while-drilling module 134 can also include
components for generating electrical power for the down hole
equipment. This can include a mud turbine generator powered by the
flow of the drilling fluid 122. However, this configuration is
provided by way of example and is not meant to limit the present
disclosure. In other embodiments, other power and/or battery
systems can be employed. The measuring-while-drilling module 134
can include one or more of the following measuring devices: a
direction measuring device, an inclination measuring device, and so
on. Further, a logging-while-drilling module 132 and/or 138 can
include one or more measuring devices, such as a weight-on-bit
measuring device, a torque measuring device, a vibration measuring
device, a shock measuring device, a stick slip measuring device,
and so forth.
[0021] In some embodiments, the wellsite system 100 is used with
controlled steering or directional drilling. For example, the
rotary steerable system 136 is used for directional drilling. As
used herein, the term "directional drilling" describes intentional
deviation of the wellbore from the path it would naturally take.
Thus, directional drilling refers to steering the drill string 104
so that it travels in a desired direction. In some embodiments,
directional drilling is used for offshore drilling (e.g., where
multiple wells are drilled from a single platform). In other
embodiments, directional drilling enables horizontal drilling
through a reservoir, which enables a longer length of the wellbore
to traverse the reservoir, increasing the production rate from the
well. Further, directional drilling may be used in vertical
drilling operations. For example, the drill bit 118 may veer off of
a planned drilling trajectory because of the unpredictable nature
of the formations being penetrated or the varying forces that the
drill bit 118 experiences. When such deviation occurs, the wellsite
system 100 may be used to guide the drill bit 118 back on
course.
[0022] The drill string 104 can include one or more extendable
displacement mechanisms, such as a piston mechanism that can be
actuated by an actuator to displace a pad toward, for instance, a
borehole wall to cause the bottom hole assembly 116 to move in a
desired direction of deviation. In embodiments of the disclosure, a
displacement mechanism can be actuated by the drilling fluid 122
routed through the drill string 104. For example, the drilling
fluid 122 is used to move a piston, which changes the orientation
of the drill bit 118 (e.g., changing the drilling axis orientation
with respect to a longitudinal axis of the bottom hole assembly
116). The displacement mechanism may be employed to control a
directional bias and/or an axial orientation of the bottom hole
assembly 116. Displacement mechanisms may be arranged, for example,
to point the drill bit 118 and/or to push the drill bit 118. In
some embodiments, a displacement mechanism is deployed by a
drilling system using a rotary steerable system 136 that rotates
with a number of displacement mechanisms. It should be noted that
the rotary steerable system 136 can be used in conjunction with
stabilizers, such as non-rotating stabilizers, and so on.
[0023] In some embodiments, a displacement mechanism can be
positioned proximate to the drill bit 118. However, in other
embodiments, a displacement mechanism can be positioned at various
locations along a drill string, a bottom hole assembly, and so
forth. For example, in some embodiments, a displacement mechanism
is positioned in a rotary steerable system 136, while in other
embodiments, a displacement mechanism can be positioned at or near
the end of the bottom hole assembly 116 (e.g., proximate to the
drill bit 118). In some embodiments, the drill string 104 can
include one or more filters that filter the drilling fluid 122
(e.g., upstream of the displacement mechanism with respect to the
flow of the drilling fluid 122).
[0024] Referring now to FIGS. 2 through 5, example systems and
apparatus are described that can provide wear resistant
functionality to a tool or equipment, such as to portions of the
wellsite system 100 described with reference to FIG. 1. For
instance, the example systems and apparatus can provide a wear
resistant part that can be included in a valve (e.g., a rotary
valve used to select flow paths for operational fluids of the drill
string 104), a piston (e.g., a piston used to actuate the
extendable displacement mechanism of the drill string 104, a piston
used to change the orientation of the drill bit 118, or so forth),
a flow channel (e.g., a flow channel used to convey drilling fluid
122), a bearing (e.g., a bearing used in the rotary swivel 114, a
bearing used in a rotary component of the drill string 104, such as
the rotary steerable system 136, or so forth), a filter (e.g., a
filter for the drilling fluid 122, such as upstream of the
displacement mechanism with respect to the flow of the drilling
fluid 122), a stabilizer (e.g., a stabilizer used in conjunction
with the rotary steerable system 136), a flow diverter, or other
tools or system. A wear resistant part 200 includes a first
material 202 having a structure 204, where the first material 202
can maintain the structure 204 at high temperatures, such as high
infiltration temperatures (e.g., stable at temperatures at and
exceeding about 800.degree. C., stable from about 1000.degree. C.
to about 1500.degree. C., stable from about 1100.degree. C. to
about 1300.degree. C., or so forth). In embodiments, the first
material 202 can include, but is not limited to, a ceramic
material, a sintered tungsten carbide material, a powder-based
material (e.g., with a binder, without a binder), or combinations
thereof. The ceramic material can include, but is not limited to,
alumina (e.g., Al.sub.2O.sub.3 having a purity of about 95% or
higher), high purity alumina (Al.sub.2O.sub.3 having a purity of
above about 99%), or the like. The powder-based material can
include, but is not limited to, a tungsten carbide powder, a
molybdenum alloy powder, a copper powder, or the like. The binder
can include, but is not limited to, a cobalt-based binder, a copper
alloy binder, combinations thereof, or the like. For instance,
ceramic materials, sintered tungsten carbide materials, and other
powder-based materials can maintain structural integrity during an
infiltration process (e.g., involving infiltrated tungsten carbide)
at temperatures ranging from 1000.degree. C. to 1500.degree. C.,
whereas in some instances, diamond materials (e.g., portions of
polycrystalline diamond compact materials) could convert to
graphite at high infiltration temperatures (e.g., temperatures at
and above 800.degree. C.).
[0025] The first material 202 also defines at least one surface
feature 206. FIGS. 2 through 5 each show the surface feature 206 as
a flow channel (e.g., a linear flow channel shown in FIGS. 2 and 3,
a non-linear flow channel shown in FIGS. 4 and 5). However, a flow
channel is provided by way of example of the surface feature 206,
and is not meant to limit the present disclosure. For example, in
embodiments, the surface feature 206 is a high tolerance feature,
such as an operating surface of the wear resistant part 200,
including, but not limited to, a running surface, a bushing
surface, a linear flow channel, a nonlinear flow channel, or so
forth. Moreover, the surface feature 206 can include a plurality of
flow channels, operating surfaces, or combinations thereof to
provide highly toleranced and scalable components that can
withstand high infiltration temperatures. In embodiments, a "high
tolerance feature" can be understood to refer to a feature spacing
between mating parts on the order of microns (e.g., ranging from
between about 0 microns to about 100 microns). For example, in one
instance of a high tolerance feature, when a cylindrical rotating
part has a diameter of at least approximately 30 mm, the spacing
between the outer circumferential surface of the rotating part and
an inner circumferential surface of bearing that receives the
rotating part can be a distance of at least approximately 5
microns.
[0026] The wear resistant part 200 also includes a second material
208 formed into a shape 210 extending partially around the
structure 204 of the first material 202 while exposing the surface
feature 206 of the first material 202. For example, the flow
channels shown in FIGS. 2 through 5 remain exposed while the second
material 208 is formed into the shape 210 extending partially
around the structure 204 of the first material 202. An exposed
portion of the surface feature 206 can then interact with another
structure, such as a part 214, to provide functionality as a tool
component or system component, such as through providing an
operating surface with which to interface. For example, the part
214 can facilitate selection or operation of the flow channels
formed by the surface feature 206 of the first material 202 by
rotation of the part 214 relative to the wear resistant part 200.
The first material can be machined, molded, formed, or otherwise
shaped, where a subsequent infiltration technique (e.g., an
infiltration molding process) can connect (e.g., bond) the first
material 202 with the second material 208. For example, the first
material 202 can be machined, molded, formed, or otherwise shaped
into the structure 204 (e.g., an insert portion) that includes the
surface feature 206, where the structure 204 is connected to the
second material 208 that is shaped into the shape 210 by
infiltration of the second material 208 and where the second
material 208 extends partially around the structure 204 of the
first material 202 to expose the surface feature 206 of the first
material 202. In embodiments, the second material 208 can be the
same as the first material 202, can differ from the first material
202, or combinations thereof. For example, the second material can
include an infiltrated tungsten carbide material.
[0027] The shape 210 of the second material 208 is formable by a
matrix infiltration at a high infiltration temperature at which the
structure of first material retains structural integrity. The high
infiltration temperature can be at a temperature above about
800.degree. C. For example, in some embodiments, the high
infiltration temperature is a temperature from about 1,000.degree.
C., 1,010.degree. C., 1,020.degree. C., 1,030.degree. C.,
1,040.degree. C., 1,050.degree. C., 1,060.degree. C., 1,070.degree.
C., 1,080.degree. C., 1,090.degree. C., 1,100.degree. C.,
1,110.degree. C., 1,120.degree. C., 1,130.degree. C., 1,140.degree.
C., 1,150.degree. C., 1,160.degree. C., 1,170.degree. C.,
1,180.degree. C., 1,190.degree. C., 1,200.degree. C., 1,210.degree.
C., 1,220.degree. C., 1,230.degree. C., 1,240.degree. C.,
1,250.degree. C., 1,260.degree. C., 1,270.degree. C., 1,280.degree.
C., 1,290.degree. C., 1,300.degree. C., 1,310.degree. C.,
1,320.degree. C., 1,330.degree. C., 1,340.degree. C., 1,350.degree.
C., 1,360.degree. C., 1,370.degree. C., 1,380.degree. C.,
1,390.degree. C., 1,400.degree. C., 1,410.degree. C., 1,420.degree.
C., 1,430.degree. C., 1,440.degree. C., 1,450.degree. C.,
1,460.degree. C., 1,470.degree. C., 1,480.degree. C., or
1,490.degree. C. to a temperature of about 1,010.degree. C.,
1,020.degree. C., 1,030.degree. C., 1,040.degree. C., 1,050.degree.
C., 1,060.degree. C., 1,070.degree. C., 1,080.degree. C.,
1,090.degree. C., 1,100.degree. C., 1,110.degree. C., 1,120.degree.
C., 1,130.degree. C., 1,140.degree. C., 1,150.degree. C.,
1,160.degree. C., 1,170.degree. C., 1,180.degree. C., 1,190.degree.
C., 1,200.degree. C., 1,210.degree. C., 1,220.degree. C.,
1,230.degree. C., 1,240.degree. C., 1,250.degree. C., 1,260.degree.
C., 1,270.degree. C., 1,280.degree. C., 1,290.degree. C.,
1,300.degree. C., 1,310.degree. C., 1,320.degree. C., 1,330.degree.
C., 1,340.degree. C., 1,350.degree. C., 1,360.degree. C.,
1,370.degree. C., 1,380.degree. C., 1,390.degree. C., 1,400.degree.
C., 1,410.degree. C., 1,420.degree. C., 1,430.degree. C.,
1,440.degree. C., 1,450.degree. C., 1,460.degree. C., 1,470.degree.
C., 1,480.degree. C., 1,490.degree. C., or 1,500.degree. C. The
matrix infiltration process can include a standard atmosphere for
infiltration of the second material. In embodiments, the matrix
infiltration process can include a controlled atmosphere, such as
an oxygen purge during infiltration of the second material, use of
a flux during infiltration, or so forth. An oxygen purge can remove
oxygen from the infiltration environment as a potential reactant
with materials involved in the matrix infiltration process (e.g.,
surfaces of the first material 202, metalized surfaces (described
further herein), or so forth).
[0028] In embodiments, a surface 212 of the first material 202 in
contact with the second material 208 is metalized. The surface 212
can be metalized to facilitate connection between the first
material 202 and the second material 208 during a process used to
bond the first material 202 with the second material. The process
can include, for example, a matrix infiltration process (e.g.,
matrix infiltration process used to form the shape 210 of the
second material), a brazing process, or combinations thereof. For
example, when the first material 202 is machined, molded, formed,
or otherwise shaped to provide the structure 204 and surface
feature 206, the surface 212 can be metalized for bonding the first
material 202 to the second material 208 during matrix infiltration,
during a brazing process, or combinations thereof. In some
embodiments, the surface 212 is metalized to provide a sealed
surface between the first material 202 and the second material 208
following a process to join the first material 202 and the second
material 208 (e.g., infiltration process, brazing process, or so
forth). For example, a metalized surface on a ceramic component can
provide a sealed surface between the ceramic component and an
infiltrated tungsten carbide material following a matrix
infiltration of the tungsten carbide material, following a brazing
process, or so forth. In embodiments, the metal applied to the
surface 212 can be the same as, or metallurgically similar to, an
infiltration binding material used to infiltrate the second
material 208, which can facilitate a complete bond between the
first material 202 and the second material 208. For example, a
metallurgically similar metal can include, but is not limited to, a
metal having a similar metal composition, lattice structure,
crystal structure, or the like. A brazing process used to bond the
first material 202 and the second material 208 via the surface 212
that is metalized can provide a removable, sealed running
surface.
[0029] Referring to FIGS. 2 and 3, the wear resistant part 200 is
shown with the part 214 in an internal portion 216 of the wear
resistant part 200 and exploded therefrom, respectively. The
structure 204 of the wear resistant part 200 provides the surface
feature 206 in the form of a linear flow channel extending through
the structure 204, providing access to the interior portion 216.
For example, the structure 204 can be formed from a ceramic
material, a sintered tungsten carbide material, or other
powder-based material (e.g., with a binder, without a binder), or
combinations thereof and machined, molded, formed, or otherwise
shaped to provide the structure 204 and surface feature 206. The
second material 208 is formed into the shape 210 (e.g., with an
approximately cylindrical exterior) extending partially around the
structure 204 while exposing the surface feature 206, such as to
permit access to the surface feature 206 from the interior portion
216, from an exterior access region 218, other access regions, or
combinations thereof. For example, the structure 204 can be placed
into a mold and the second material 208 is infiltrated to form the
shape 210 around the structure 204 (while maintaining exposure of
the surface feature 206) to bind the first material 202 and the
second material 208. When the part 214 is positioned in the
interior portion 216, the part 214 can facilitate selection or
operation of the flow channels formed by the surface feature 206 of
the first material 202 by rotation of the part 214 relative to the
wear resistant part 200 within the interior portion 216, such as by
aligning one or more ports 220 formed in the part 214 with one or
more flow channels formed by the surface feature 206 in the
structure 204.
[0030] Referring to FIGS. 4 and 5, the wear resistant part 200 is
shown with the part 214 in the internal portion 216 of the wear
resistant part 200 and exploded therefrom, respectively. The
structure 204 of the wear resistant part 200 provides the surface
feature 206 in the form of a linear flow channel 222 extending
through the structure 204, providing access to the interior portion
216, and in the form of a nonlinear flow channel 224 providing
access to the interior portion 216 from a bottom access region 226.
For example, the structure 204 can be formed from a ceramic
material, a sintered tungsten carbide material, or other
powder-based material (e.g., with a binder, without a binder), or
combinations thereof and machined, molded, formed, or otherwise
shaped to provide the structure 204 and surface feature 206. The
second material 208 is formed into the shape 210 (e.g., with an
approximately cylindrical exterior) extending partially around the
structure 204 while exposing the surface feature 206, such as to
permit access to the surface feature 206 from the interior portion
216, from the exterior access region 218, from the bottom access
region 226, from other access regions, or combinations thereof. For
example, the structure 204 can be placed into a mold and the second
material 208 is infiltrated to form the shape 210 around the
structure 204 (while maintaining exposure of the surface feature
206) to bind the first material 202 and the second material 208.
When the part 214 is positioned in the interior portion 216, the
part 214 can facilitate selection or operation of the linear flow
channel 222 and the nonlinear flow channel 224 formed by the
surface feature 206 of the first material 202 by rotation of the
part 214 relative to the wear resistant part 200 within the
interior portion 216, such as by aligning one or more ports 220
formed in the part 214 with the linear flow channel 222, the
nonlinear flow channel 224, or combinations thereof.
[0031] Referring now to FIG. 6, a procedure 600 is described in an
example embodiment in which a wear resistant part is formed from a
first material and a second material. At block 610, a structure,
such as the structure 104, having one or more surface features,
such as the surface feature 106, is received, where the structure
is formed of a first material, such as a ceramic material, a
sintered tungsten carbide material, or powder-based material, or
combinations thereof, capable of maintaining the structure at a
temperature from about 1000.degree. C. to about 1500.degree. C. At
block 620, matrix infiltration at a temperature from about
1000.degree. C. to about 1500.degree. C., is used to form a second
material, such as an infiltrated tungsten carbide material, into a
shape that can extend partially around the structure of the first
material while exposing the surface feature of the first material.
At block 630, the second material is connected to the first
material. In some embodiments, at block 632, the second material
can be formed partially around the first material by the matrix
infiltration. As described herein, one or more surfaces of the
first material may be metalized for bonding with the second
material during the matrix infiltration. In some embodiments, at
block 634, the first material can be brazed to the second material
(e.g., when one or more surfaces of the first material are
metalized).
[0032] The foregoing outlines features of several embodiments so
that those skilled in the art may better understand the aspects of
the disclosure. Those skilled in the art should appreciate that
they may readily use the disclosure as a basis for designing or
modifying other processes and structures for carrying out the same
purposes and/or achieving the same advantages of the embodiments
introduced herein. Additionally, it should be understood that
references to "one embodiment" or "an embodiment" of the present
disclosure are not intended to be interpreted as excluding the
existence of additional embodiments that also incorporate the
recited features. For example, features shown in individual
embodiments referred to above may be used together in combinations
other than those which have been shown and described specifically.
Accordingly, any such modification is intended to be included
within the scope of this disclosure. In the claims,
means-plus-function clauses are intended to cover the structures
described herein as performing the recited function and not just
structural equivalents, but also equivalent structures. Thus,
although a nail and a screw may not be structural equivalents in
that a nail employs a cylindrical surface to secure wooden parts
together, whereas a screw employs a helical surface, in the
environment of fastening wooden parts, a nail and a screw may be
equivalent structures. It is the express intention of the applicant
not to invoke means-plus-function for any limitations of any of the
claims herein, except for those in which the claim expressly uses
the words `means for` together with an associated function.
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